The KTM LC4 Reliability research thread

Discussion in 'Thumpers' started by demononthebrakes, May 25, 2006.

  1. gunnerbuck

    gunnerbuck Island Hopper

    Joined:
    Nov 19, 2005
    Oddometer:
    6,637
    Location:
    N.V.I, B.C.
    1- 640 Adventure
    2- 2003
    3-Bought new in 04
    4- 116,000 KM
    5- Mods, 155 main jet, 55W acc. light
    6- Work history- 4 float needle + seat replacements, 5 needle jet/ 4 jet needle replacements, Replace slide + membrane, replace cam bearing, exhaust follower bearing replaced twice, Intake follower will be replaced a third time, rebuild waterpump 3 times, replace countershaft seal twice + o -ring 4 times, replace crankshaft + bearings, replace piston and replate cylinder, 2 valve jobs, replace leaky headgasket, reseal leaky rocker cover a couple times, fix electrical gremlins periodicly caused mostly by vibration/chafing, Replace rear wheel bearings 4 times/ twice front, Renew fork seals twice, fatigue replacement of front engine mount bolt + L.S. fairing mount bracket, 8th chain/sprocket set combo coming up, rebuild clutch master cylinder....... Update: Replace worn starter clutch, replace clutch slave O-ring
    7- upgrades done- Moto-sport frames + yukon bags, homemade tail rack extension
    8- tires- Currently on the 17th rear a Mt 21, 13th front VRM 147...
    9- Slab VS Dirt- 50/50
    10- Same bike again? Sure, best bike out there for my needs....
    11- Not yet...



    [​IMG]
    #61
  2. mikeprod92211

    mikeprod92211 Desert Rat

    Joined:
    Apr 30, 2004
    Oddometer:
    594
    Yes I found the longevity thread in the 640 LC4 thread link but I was hoping to get a little more specific.
    I would like to see the following information from LC4 owners (past or present).
    1. Bike: LC4E
    2. Year:2000
    3. Bought used or new:used
    4. Current mileage:27000+
    5. Modifications done:Carb needle adjusted, easternbeaver.com headlight wiring harness with dual relays, 525 exc headlight, my own muffler mods for more airflow, Loaded bar risers, Loaded fuel screw, Spitfire windshield, Komfort seat (2nd), Enduro Engineering rear disc guard, Kissan rear light flasher, LED additional rear brake lights....
    6. Mechanical work done:Starter clutch replacement
    7. Upgrades done:Soon...rear shock rebuild, new front fork springs
    8. Current tires on the bike:IRC GP 110's
    9. Percentage of road versus dirt use:60/40
    10. Would you buy another one?:Waiting for the 690 Adv
    11. Did you replace the main shaft bearing (if applicable):no
    12. Pic of the bike if available:need to downsize the pic!
    #62
  3. G.Kennedy

    G.Kennedy ...

    Joined:
    Oct 10, 2002
    Oddometer:
    1,857
    Location:
    LA, CA
    1. Bike: 640 Adventure
    2. Year: 2002
    3. Bought used or new: Used (had 5000 on it)
    4. Current mileage: 22,500 miles
    5. Modifications done: Precision Concepts revalve/respring, Seat by Rocky Mayer, SXC can, Pastrana Pro Tapers, Scott Stabilizer, Supermoto fender ... etc...
    6. Mechanical work done: Bearing upgrade, carb rebuild .... lube everything
    7. Upgrades done: see above
    8. Current tires on the bike: Dunlop 606 Rear .. Sahara front (kinda burning though old take offs commuting right now)
    9. Percentage of road versus dirt use: 50% dirt - 50% street
    10. Would you buy another one?: Absolutely ... would love to have a backup.
    11. Did you replace the main shaft bearing (if applicable): Yep ... original looked fine though
    12. Pic of the bike if available:
    [​IMG]
    #63
  4. exiliadodecordoba

    exiliadodecordoba Santiago Valinoti Loza

    Joined:
    May 29, 2008
    Oddometer:
    45
    Location:
    Rio de Janeiro, Brasil - Patagonia, Argentina
    Hi, my name is Santiago. Im from Cordoba, Argentina. But im living in Rio de Janeiro, Brasil. I travelled with my KTM from Mendoza (ARG) to Rio de Janeiro (BRASIL) in 5 days... 1000km a day... just cheking oil and tires... the 640 lc4 adventure is a perfect engine for long trips...

    1. Bike: 640 LC4 Adventure
    2. Year:2006
    3. Bought used or new: used with 3000 km
    4. Current mileage: 12000 km
    5. Modifications done: no
    6. Mechanical work done: no
    7. Upgrades done: GPS
    8. Current tires on the bike: Metzeler Karoo MCE
    9. Percentage of road versus dirt use: 50%50%
    10. Would you buy another one?: yes.. but i could prefer check the new 690 rally desert
    11. Did you replace the main shaft bearing (if applicable): no
    12. Pic of the bike if available:

    Attached Files:

    #64
  5. SCsurfer

    SCsurfer surfing explorer

    Joined:
    Sep 3, 2007
    Oddometer:
    174
    Location:
    San Clemente
    1. Bike: 640 Adventure
    2. Year: 2007
    3. New or used: New
    4. Current mileage: 5200 mi
    5. Modifications: Standard carb mods , open air box , Leo Vice pipe
    6. Mechanical work: Normal service
    7. Upgrades: Renazco seat , Scotts steering stabilizer, headlight wiring upgrade ala Eastern Beaver relay harness, Odessy battery, Wolfman tank bag, Pro Moto Billet rear rack.
    8. Current Tires: Rear TKC 80, Front Metzler Karoo
    9. Percentage Road to Dirt: 70% road / 30% dirt
    10. Would you buy another: Without hesitation
    11. Did you replace main shaft bearing: N/A
    #65
  6. Tappet

    Tappet Feral

    Joined:
    May 7, 2007
    Oddometer:
    1,451
    Location:
    South Africa
    1. Bike: 640 Adv
    2. Year: 07
    3. Bought used or new: New in 08 (I have a hang-up about that)
    4. Current mileage: 20500km
    5. Modifications done: High fender, akra, risers etc etc here
    6. Mechanical work done: Removed euro restrictions
    7. Upgrades done: here
    8. Current tires on the bike: Michelin deserts
    9. Percentage of road versus dirt use: 60/40 dirt/tarmac
    10. Would you buy another one?: Yes, the 690 version when it arrives
    11. Did you replace the main shaft bearing (if applicable): Nope
    12. Pic of the bike if available:

    [​IMG]

    [​IMG]
    #66
  7. braaap!

    braaap! Long timer Supporter

    Joined:
    Mar 16, 2005
    Oddometer:
    4,379
    Location:
    Here and There
    1. Bike: 640A
    2. Year: 2004
    3. Bought used or new: New
    4. Current mileage: 48500kms
    5. Modifications done:
    • high front guard (SM)
    • ktm side stand
    • barkbusters
    • replaced shit Behr rims with excel / morad rims
    • loaded's underbar damper mount and risers (scotts damper)
    • loaded's bst screw / slide drilled / bst rejetted
    • ktm airbox - open side cover
    • all anti pollution crap removed
    • HID lights
    • heated grips / throttle lock
    • low octane fuel - dash switch
    • dash GPS mount / hardwired power / switch w/led indicator
    • pivot pegs
    • revalved forks / shock - heavier springs added
    • clear hiflow fuel filter
    • motech pannier racks
    • water and fuel tanks
    • home made rack plate
    6. Mechanical work done:
    • regular services / oil changes / loctite :D
    • replaced front and rear wheel bearings / seals - 25000kms
    • replaced neutral indicator switch - 32000kms
    • replaced all shock linkage bearings / shafts / seals- 35000kms
    • replaced rear caliper - 35000kms
    • replaced inlet valve train - 35000kms :huh
    • replaced starter spragg clutch - 45000kms
    • replaced countershaft o-ring - twice
    • replaced worn slide / needle / mainjet - 45000kms
    • helicoiled case - M12 drain plug (damn ham fisted mechanic!)
    • to do: front to back strip down scheduled @ 50000kms
    7. Upgrades done: see #5
    8. Current tires on the bike: Dunlop 908RR F&R
    9. Percentage of road versus dirt use: 60/40
    10. Would you buy another one?: Nah! hoping for the 690A... or an SE
    11. Did you replace the main shaft bearing (if applicable): n/a
    12. Pic of the bike if available:
    13. 640 wishlist: FCR / 6th gear / oil cooler / 2litres oil capacity / +10 hp

    [​IMG]
    #67
  8. overlandr

    overlandr Dystopist

    Joined:
    Nov 30, 2003
    Oddometer:
    6,021
    Location:
    Sydney
    Keep posting guys!
    #68
  9. billy bee

    billy bee AAdventurer

    Joined:
    Sep 8, 2004
    Oddometer:
    1,402
    Location:
    Big Ditch, CA
    1. Bike: 640 E
    2. Year: 2001
    3. Bought used or new: Used
    4. Current mileage: 11,000
    5. Modifications done:
    • SW Motech side stand
    • Fastway pegs
    • Motard wheels and tires
    • Airbox screen,
    • jets,
    • Loaded mount and riser for scotts dampner,
    • billet rack
    • KTM supermoto pipe
    6. Mechanical work done: basic maintenance
    7. Upgrades done: What's the difference between upgrades and mods?
    8. Current tires on the bike: Pirelli Diabalo
    9. Percentage of road versus dirt use: 99% street since motard wheels went on
    10. Would you buy another one?: In a freaking heartbeat
    11. Did you replace the main shaft bearing (if applicable): Was done by PO
    12. Pic of the bike if available:
    #69
  10. Newner

    Newner Buffering

    Joined:
    Jan 11, 2008
    Oddometer:
    2,511
    Location:
    Bixby, OK
    1. Bike: 620 SC
    2. Year: 1995
    3. Bought used or new: Used
    4. Current mileage: 4,000 miles ????maybe????
    5. Modifications done: Removed instrument cluster and for a GPS only Mount
    6. Mechanical work done: Delorto Carb is always fowling up but its fixed now.
    7. Upgrades done: added that pretty orange tail rack
    9. Percentage of road versus dirt use: 90%
    10. Would you buy another one?: Yep anyone want to trade a 690 for a V-strom
    11. Did you replace the main shaft bearing (if applicable): Nope (what you don't know won't hurt you)
    12. Pic of the bike if available:

    [​IMG]

    Also besides that Main Shaft Bearing problem does anyone know of any other mechanical issues I should be aware of with this bike???
    #70
  11. yazoo

    yazoo n00b

    Joined:
    Jul 22, 2007
    Oddometer:
    1
    1. Bike: 640 Adv
    2. Year: 2005
    3. Bought used or new: Used
    4. Current mileage: 25K km
    5. Modifications done: Stock crb jetted, planning to add extra fan
    6. Mechanical work done: not yet, need to replace motor starter
    7. Upgrades done: no, but planning to install fcr mx 39mm
    9. Percentage of road versus dirt use: 95% Road
    10. Would you buy another one?: Depends on the follow up model
    11. Did you replace the main shaft bearing (if applicable): No
    12. Pic of the bike if available: will upload shortly
    #71
  12. jfn68

    jfn68 Banned

    Joined:
    Aug 27, 2004
    Oddometer:
    620
    [​IMG]http://i666.photobucket.com/albums/vv23/joedirtsbrother/Picture002-1.jpg?t=1237379531
    1 660 rallye
    2 2000
    3 used
    4 unknown...done 15000km since i got it in 04,did full chassis/engine rebuild on it
    5 4860 wp/larger remote resivior with h/l dampning adj,talon hubs/tagasako rims/msc steering dampner,triple clamp,vapour speedo/trip meter
    6 general service,run semi syn 15/50 shell oil
    7 no upgrades planned
    8 99% dirt
    9 like a later one,but they are very expensive.
    10 yes....but had one in it
    #72
  13. 1stworks

    1stworks dude

    Joined:
    Jun 25, 2004
    Oddometer:
    1,616
    Location:
    south side
    1. Bike: KTM 625 SXC
    2. Year: 2003
    3. Bought used or new: used
    4. Current mileage: 5000
    5. Modifications done: none
    6. Mechanical work done: reseal rocker cover
    7. Upgrades done: Lights/GPR/Renzco seat/Big gas tank/peg extenders
    8. Current tires on the bike:606 front MT 21 rear
    9. Percentage of road versus dirt use:20% road 80% dirt
    10. Would you buy another one?: maybe it my 2nd on
    11. Did you replace the main shaft bearing (if applicable):no
    12. Pic of the bike if available:yes

    when i first got it

    [​IMG]

    then this

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    <EMBED id=VideoPlayback style="WIDTH: 400px; HEIGHT: 326px" src=""http://video.google.com/googleplayer.swf?docid=2191292773135197691&hl=en&fs=true type=application/x-shockwave-flash p <>




    firstworks
    #73
  14. braaap!

    braaap! Long timer Supporter

    Joined:
    Mar 16, 2005
    Oddometer:
    4,379
    Location:
    Here and There
    so that's what that tinkling noise was at 52500kms....

    [​IMG]


    [​IMG]

    and the head.... ugly eh!
    #74
  15. meat popsicle

    meat popsicle Ignostic

    Joined:
    Feb 9, 2004
    Oddometer:
    14,587
    Location:
    Circumlocution Office of Little Dorrit
    You've got double the mileage I do, so I can't feel sorry for ya. :nah Jealous maybe. Remember mine's an 03 (bought in 04). :cry
    #75
  16. braaap!

    braaap! Long timer Supporter

    Joined:
    Mar 16, 2005
    Oddometer:
    4,379
    Location:
    Here and There
    Hey there Meat :wave
    ! just didn't need this right now... s'pose I'll pull it right down and refresh all the bits that go round and round and in and out....

    It can't be attributed to poor fuel either... I'll be checking the bypass valve for a sticking spring too, last month had a little gearbox oil in the airbox (never had that before, well maybe after some foolish wheelies)... it might be a early warning sign of impending engine damage on these things?...

    engine oil not reticulating 100%.... high temperatures... hard running.... metal fatigue on bits that have been pumping up and down for many hours... tinkle, tinkle... kaboom!

    I'm still amazed how these motors continue to run with such damage!
    #76
  17. jfn68

    jfn68 Banned

    Joined:
    Aug 27, 2004
    Oddometer:
    620
    have a good look at the oil pumps,any gouges/grooves cause lost displacment....my 2 were rooted from contamination...expensive and hard to get (in oz )
    #77
  18. braaap!

    braaap! Long timer Supporter

    Joined:
    Mar 16, 2005
    Oddometer:
    4,379
    Location:
    Here and There
    will do! thx for the heads up...
    #78
  19. meat popsicle

    meat popsicle Ignostic

    Joined:
    Feb 9, 2004
    Oddometer:
    14,587
    Location:
    Circumlocution Office of Little Dorrit
    I am very curious too about that bypass valve; Its the only thing I can think of that might be responsible for my unreliable oil sight glass levels.

    I too am amazed at how much abuse the LC4 can take and keep on running. Either that or I am a better mechanic than I give myself credit for... :lol3
    #79
  20. Pendragon5

    Pendragon5 Carress of Steel

    Joined:
    Jul 2, 2008
    Oddometer:
    52
    Location:
    Cheyenne WY
    1. 620RXCe
    2. 1998
    3. new
    4. 15k miles
    5. shorter suspension (29"inseam),Edelbrock off-road only mods+pumper kit:D , skid plate, opened air box, rear disc gard, 95 model tool box@charcoal can mount, geared down=1 in front+add 6 in rear (way down):D
    6. normal maint., water pump+brgs, wheel brgs/both ends many times,fork seals, all cables+speedo 10+ times?, petcock, rear axle replaced when permanent side came off, new DOT5 every year!, radiator fan, left bar switch, chain gard
    7. water pump seal, blue fork seals, fork seal skins, monster hvy duty tubes:D , brush gards, spare set of wheels:D
    8. Kenda DS+Bridgestone Knobs
    9. 80% dirt
    10. yes but, newer
    11. not yet
    #80